Acid-Soluble Cement Compositions Comprising Cement Kiln Dust and/or a Natural Pozzolan and Methods of Use

ABSTRACT

The present invention relates to acid-soluble cement compositions that comprise cement kiln dust (“CKD”) and/or a natural pozzolan and associated methods of use. An embodiment includes a method of cementing comprising: placing an acid-soluble cement composition in a subterranean formation, wherein the acid-soluble cement composition comprises a hydraulic cement, a component selected from the group consisting of CKD, pumicite, and a combination thereof, and water; allowing the acid-soluble cement composition to set; and contacting the set acid-soluble cement composition with an acid to dissolve the set acid-soluble cement composition.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.12/825,004, entitled “Acid Soluble Cement Kiln Dust CementingCompositions and Sorel Cement Compositions Using CKD and/or Pumicite andMethods of Use,” filed on Jun. 28, 2010, which is a continuation-in-partof United Stated patent application Ser. No. 12/606,381, entitled“Methods of Cementing Subterranean Formation Formations Using CementKiln Dust in Compositions Having Reduced Portland Cement Content,” filedon Oct. 27, 2009, issued as U.S. Pat. No. 7,743,828, which is acontinuation-in-part of U.S. application Ser. No. 12/420,630, entitled“Settable Compositions Comprising a Natural Pozzolan and AssociatedMethods,” filed on Apr. 8, 2009, issued as U.S. Pat. No. 7,631,692,which is a continuation-in-part of U.S. patent application Ser. No.12/349,676, “Extended Settable Compositions Comprising Cement Kiln Dustand Associated Methods,” filed on Jan. 7, 2009, issued as U.S. Pat. No.7,674,332, entitled which is a divisional of U.S. patent applicationSer. No. 12/034,886, entitled “Extended Settable Compositions ComprisingCement Kiln Dust and Associated Methods, filed on Feb. 21, 2008, issuedas U.S. Pat. No. 7,478,675, which is a continuation-in-part of U.S.patent application Ser. No. 11/223,669, entitled “Settable CompositionsComprising Cement Kiln Dust and Additive(s),” filed Sep. 9, 2005, issuedas U.S. Pat. No. 7,445,669, the entire disclosures of which areincorporated herein by reference.

BACKGROUND

The present invention relates to cementing operations and, moreparticularly, in certain embodiments, to acid-soluble cementcompositions that comprise cement kiln dust (“CKD”) and/or a naturalpozzolan and associated methods of use.

Cement compositions may be used in a variety of subterraneanapplications. For example, in subterranean well construction, a pipestring (e.g., casing, liners, expandable tubulars, etc.) may be run intoa well bore and cemented in place. The process of cementing the pipestring in place is commonly referred to as “primary cementing.” In atypical primary cementing method, a cement composition may be pumpedinto an annulus between the walls of the well bore and the exteriorsurface of the pipe string disposed therein. The cement composition mayset in the annular space, thereby forming an annular sheath of hardened,substantially impermeable cement (i.e., a cement sheath) that maysupport and position the pipe string in the well bore and may bond theexterior surface of the pipe string to the subterranean formation. Amongother things, the cement sheath surrounding the pipe string functions toprevent the migration of fluids in the annulus, as well as protectingthe pipe string from corrosion. Cement compositions also may be used inremedial cementing methods, for example, to seal cracks or holes in pipestrings or cement sheaths, to seal highly permeable formation zones orfractures, to place a cement plug, and the like. Cement compositionsalso may be used in surface applications, for example, constructioncementing.

In some applications, it may be desirable for the cement composition tobe acid soluble. For instance, an acid-soluble cement composition may bedesirable in applications where it is anticipated that the hardenedcement will be removed in subsequent well bore operations. Oneparticular application includes use of an acid-soluble cementcomposition to plug permeable zones in a formation that may allow theundesired flow of fluid into, or from, the well bore. For example, thepermeable zones may result in the loss of circulation of fluids, such asa drilling fluid or a cement composition, in the well bore or anundesired influx of gas or water into the well bore. The permeable zonesinclude, for example, vugs, voids, fractures (natural or otherwiseproduced) and the like. Other applications for acid-soluble cementcompositions include, for example, the formation of annular plugs andisolation of gravel-packed well bore intervals. Examples of acid-solublecement compositions include those comprising Sorel cements and Portlandcements.

SUMMARY

The present invention relates to cementing operations and, moreparticularly, in certain embodiments, to acid-soluble cementcompositions that comprise CKD and/or a natural pozzolan and associatedmethods of use.

An embodiment of the present invention provides a method of cementing.The method may comprise placing an acid-soluble cement composition in asubterranean formation. The acid-soluble cement composition may comprisea hydraulic cement, a component selected from the group consisting ofcement kiln dust, pumicite, and a combination thereof, and water. Themethod may further comprise allowing the acid-soluble cement compositionto set. The method may further comprise contacting the set acid-solublecement composition with an acid to dissolve the set acid-soluble cementcomposition.

Another embodiment of the present invention provides a method ofcementing. The method may comprise placing an acid-soluble cementcomposition in a subterranean formation. The acid-soluble cementcomposition may comprise Portland cement, cement kiln dust, anacid-soluble filler, and water. The method may further comprise allowingthe cement composition to set. The method may further comprisecontacting the set acid-soluble cement composition with an acid todissolve the set acid-soluble cement composition.

Yet another embodiment of the present invention provides a cementcomposition comprising: hydraulic cement; a component selected from thegroup consisting of cement kiln dust, pumicite, and a combinationthereof; and water. The cement composition may be acid-soluble.

The features and advantages of the present invention will be readilyapparent to those skilled in the art. While numerous changes may be madeby those skilled in the art, such changes are within the spirit of theinvention.

DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention relates to cementing operations and, moreparticularly, in certain embodiments, to acid-soluble cementcompositions that comprise CKD and/or a natural pozzolan and associatedmethods of use.

There may be several potential advantages to the methods andcompositions of the present invention, only some of which may be alludedto herein. One of the many potential advantages of embodiments of thepresent invention is that the inclusion of the CKD and/or naturalpozzolan in the acid-soluble cement composition should reduce the amountof, or potentially eliminate, a higher cost additive, such as Portlandor Sorel cement, resulting in a more economical cement composition.Another potential advantage of embodiments of the present invention isthat reduction of the amount of Portland cement should reduce the carbonfootprint of the acid-soluble cement composition.

Embodiments of the acid-soluble cement compositions of the presentinvention may comprise: a hydraulic cement; a component selected fromthe group consisting of CKD, a natural pozzolan, and a combinationthereof; and water. In an embodiment, the hydraulic cement may compriseSorel cement. In another embodiment, the cement compositions may furthercomprise an acid-soluble filler. In yet another embodiment, the cementcompositions may further comprise a source of calcium ions (e.g.,hydrated lime). Other optional additives may also be included inembodiments of the cement compositions of the present invention asdesired, including, but not limited to, fly ash, slag cement,metakaolin, shale, zeolite, combinations thereof, and the like.Additionally, embodiments of the cement compositions of the presentinvention may be foamed and/or extended as desired by those of ordinaryskill in the art.

The acid-soluble cement compositions of the present invention shouldhave a density suitable for a particular application as desired by thoseof ordinary skill in the art, with the benefit of this disclosure. Insome embodiments, the cement compositions of the present invention mayhave a density in the range of from about 8 pounds per gallon (“ppg”) toabout 16 ppg. In other embodiments, the cement compositions may befoamed to a density in the range of from about 8 ppg to about 13 ppg.

Embodiments of the acid-soluble cement compositions of the presentinvention may comprise a hydraulic cement. A variety of hydrauliccements may be utilized in accordance with the present invention,including, but not limited to, those comprising calcium, aluminum,silicon, oxygen, iron, and/or sulfur, which set and harden by reactionwith water. Suitable hydraulic cements include, but are not limited to,Sorel cements, Portland cements, pozzolana cements, gypsum cements, highalumina content cements, slag cements, silica cements, and combinationsthereof. In certain embodiments, the hydraulic cement may comprise aPortland cement. In some embodiments, the Portland cements that aresuited for use in the present invention are classified as Classes A, C,G, and H cements according to American Petroleum Institute, APISpecification for Materials and Testing for Well Cements, APISpecification 10, Fifth Ed., Jul. 1, 1990. In addition, in someembodiments, cements suitable for use in the present invention may beclassified as ASTM Type I, II, or III. As will be discussed in moredetail below, acid-soluble fillers can be used with hydraulic cements(such as Portland cement) that do harden into an acid-soluble mass.

Where present, the hydraulic cement generally may be included in theacid-soluble cement compositions in an amount sufficient to provide thedesired compressive strength, density, and/or cost. In accordance withembodiments, at least a portion of the hydraulic cement may be replacedwith CKD and/or a natural pozzolan. In an embodiment, at a least aportion of the hydraulic cement is replaced with CKD and/or a naturalpozzolan. In some embodiments, the hydraulic cement may be present inthe cement compositions of the present invention in an amount in therange of 0% to about 99% by weight of cementitious components.Cementitious components include those components or combinations ofcomponents of the cement compositions that hydraulically set, orotherwise harden, to develop compressive strength, including, forexample, Sorel cement, Portland cement, CKD, fly ash, pumice, slag,lime, shale, and the like. The hydraulic cement may be present, incertain embodiments, in an amount of about 5%, about 10%, about 15%,about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%,about 90%, or about 95%. In an embodiment, the hydraulic cement may bepresent in an amount in the range of 0% to about 95% by weight ofcementitious components. In another embodiment, the hydraulic cement maybe present in an amount in the range of about 20% to about 95% by weightof cementitious components. In yet another embodiment, the hydrauliccement may be present in an amount in the range of about 50% to about90% by weight of cementitious components. One of ordinary skill in theart, with the benefit of this disclosure, will recognize the appropriateamount of the hydraulic cement to include for a chosen application.

An example of a suitable hydraulic cement comprises a Sorel cement.Sorel cements typically include magnesia-based cement systems formedfrom a mixture of magnesium oxide and magnesium chloride. However, asused herein, the term “Sorel cement” is intended to encompass any of avariety of metal oxides and soluble salts which together form ahydraulic cement. In the presence of water, the metal oxide and thesoluble salt forming the Sorel cement should solidify into anacid-soluble mass. Embodiments of the Sorel cements should rapidlydevelop a desirable compressive strength. In accordance withembodiments, at least a portion of the Sorel cement may be replaced withCKD and/or a natural pozzolan. In an embodiment, at a least a portion ofthe soluble salt is replaced with CKD and/or a natural pozzolan.

In an embodiment, the Sorel cement comprises a metal oxide. In oneparticular embodiment, the Sorel cement comprises an alkaline earthmetal oxide, such as magnesium oxide. A suitable metal oxide isTHERMATEK™ LT additive, available from Halliburton Energy Services, Inc.The metal oxide present in the Sorel cement should have an activitylevel sufficient to provide the desired reactivity. For example, thehigher the activity level of the metal oxide, the faster the reaction ofthe metal oxide with the other components of the Sorel cement to formthe hardened mass. The activity level of the metal oxide may vary basedon a number of factors. For example, the particle size differential ofthe metal oxide particles may affect the activity level. A smallerparticle size differential may result in a higher activity level due,inter alia, to a greater surface area. Another factor that may affectthe activity level of the metal oxide is a sintering process. By varyingthe heat applied during, and time of, the sintering process, metal oxidewith varying activity levels may be provided. Metal oxide that has notbeen treated by a sintering process may have a very high activity level,and thus it may be highly reactive in the Sorel cements. In anembodiment, a relatively more reactive metal oxide may be desired, suchas where it may be desired to have a cement composition with arelatively short set time, for example, when desired to rapidly seal offa permeable zone. In an alternative embodiment, a relatively lessreactive metal oxide may be desired, for example, where a delay may bedesired between mixing the cement composition and the formation of ahardened mass.

A wide variety of soluble salts are suitable for use in the Sorelcement, including metal chlorides. In one embodiment, the Sorel cementcomprises an alkaline earth metal chloride, such as magnesium chloride.An example of a suitable magnesium chloride is C-TEK additive, availablefrom Halliburton Energy Services, Inc. In an alternative embodiment, theSorel cement comprises magnesium sulfate or ammonium mono or dibasicphosphate.

In an embodiment, the Sorel cement may comprise the metal oxide and thesoluble salt in a metal-oxide-to-soluble-salt ratio of about 3:1 toabout 1:3. In another embodiment, the metal-oxide-to-soluble-salt ratiomay range from about 2:1 to about 1:2. In yet another embodiment, themetal-oxide-to-soluble-salt ratio may range from about 1.5:1 to about1:1.5. One of ordinary skill in the art will recognize the appropriateratio of the metal oxide and soluble salt to include for a particularapplication.

Embodiments of the acid-soluble cement compositions generally maycomprise CKD, which is a material generated in the manufacture ofcement. CKD, as that term is used herein, refers to a partially calcinedkiln feed which is removed from the gas stream and collected, forexample, in a dust collector during the manufacture of cement. Usually,large quantities of CKD are collected in the production of cement thatare commonly disposed of as waste. Disposal of the CKD as waste can addundesirable costs to the manufacture of the cement, as well as theenvironmental concerns associated with its disposal. The chemicalanalysis of CKD from various cement manufactures varies depending on anumber of factors, including the particular kiln feed, the efficienciesof the cement production operation, and the associated dust collectionsystems. CKD generally may comprise a variety of oxides, such as SiO₂,Al₂O₃, Fe₂O₃, CaO, MgO, SO₃, Na₂O, and K₂O. The term “CKD” is usedherein to mean cement kiln dust made as described above and equivalentforms of cement kiln dust made in other ways.

The CKD generally may exhibit cementitious properties, in that it mayset and harden in the presence of water. In accordance with embodimentsof the present invention, the CKD may be used, among other things, toreplace higher cost cementitious components, such as Portland cementand/or Sorel cement, resulting in more economical cement compositions.In addition, substitution of the CKD for the Portland and/or Sorelcement should result in a cement composition with a reduced carbonfootprint.

The CKD may be included in the acid-soluble cement compositions in anamount sufficient to provide the desired compressive strength, density,cost reduction, and/or reduced carbon footprint. In some embodiments,the CKD may be present in the cement compositions of the presentinvention in an amount in the range of from about 1% to about 100% byweight of cementitious components. For example, the CKD may be presentin an amount of about 5%, about 10%, about 15%, about 20%, about 25%,about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about60%, about 65%, about 70%, about 75%, about 80%, about 90%, or about95%. In one embodiment, the CKD may be present in an amount in the rangeof from about 5% to about 99% by weight of cementitious components. Inanother embodiment, the CKD may be present in an amount in the range offrom about 5% to about 80% by weight of cementitious components. In yetanother embodiment, the CKD may be present in an amount in the range offrom about 50% to about 80% by weight of cementitious components. One ofordinary skill in the art, with the benefit of this disclosure, willrecognize the appropriate amount of CKD to include for a chosenapplication.

Embodiments of the acid-soluble cement compositions may further comprisea natural pozzolan. Natural pozzolans are generally present on theEarth's surface and set and harden in the presence of hydrated lime andwater. Examples of natural pozzolans include pumicite, diatomaceousearth, volcanic ash, opaline shale, tuff, and combinations thereof.Generally, pumicite is a volcanic rock that exhibits cementitiousproperties, in that it may set and harden in the presence of a source ofcalcium ions and water. Hydrated lime may be used in combination withthe pumicite, for example, to provide sufficient calcium ions for thepumicite to set. The natural pozzolan may be used, among other things,to replace higher cost cementitious components, such as Portland orSorel cement, in embodiments of the sealant compositions, resulting inmore economical sealant compositions. In addition, substitution of thenatural pozzolan for the Portland cement and/or Sorel cement shouldresult in a cement composition with a reduced carbon footprint.

Where present, the natural pozzolan may be included in an amountsufficient to provide the desired compressive strength, density, costreduction and/or reduced carbon footprint for a particular application.In some embodiments, the natural pozzolan may be present in theacid-soluble cement compositions of the present invention in an amountin the range of from about 1% to about 100% by weight of cementitiouscomponents. For example, the natural pozzolan may be present in anamount of about 5%, about 10%, about 15%, about 20%, about 25%, about30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%,about 65%, about 70%, about 75%, about 80%, about 90%, or about 95%. Inone embodiment, the natural pozzolan may be present in an amount in therange of from about 5% to about 99% by weight of cementitiouscomponents. In another embodiment, the natural pozzolan may be presentin an amount in the range of from about 5% to about 80% by weight ofcementitious components. In yet another embodiment, the natural pozzolanmay be present in an amount in the range of from about 10% to about 50%by weight of cementitious components. In yet another embodiment, thenatural pozzolan may be present in an amount in the range of from about25% to about 50% by weight of cementitious components. One of ordinaryskill in the art, with the benefit of this disclosure, will recognizethe appropriate amount of the natural pozzolan to include for a chosenapplication.

The water that may be used in embodiments of the cement compositions mayinclude, for example, freshwater, saltwater (e.g., water containing oneor more salts dissolved therein), brine (e.g., saturated saltwaterproduced from subterranean formations), seawater, or combinationsthereof. Generally, the water may be from any source, provided that thewater does not contain an excess of compounds that may undesirablyaffect other components in the cement composition. In some embodiments,the water may be included in an amount sufficient to a pumpable slurry.In some embodiments, the water may be included in the cementcompositions of the present invention in an amount in the range of about40% to about 200% by weight of cementitious components. In someembodiments, the water may be included in an amount in the range ofabout 40% to about 150% by weight of cementitious components. One ofordinary skill in the art, with the benefit of this disclosure, willrecognize the appropriate amount of water to include for a chosenapplication.

Embodiments of the cement compositions may further comprise a source ofcalcium ions, such as lime. In certain embodiments, the source ofcalcium ions may include hydrated lime. The source of calcium ions maybe included in embodiments of the cement compositions, for example to,form a hydraulic composition with other components of the cementcompositions, such as the pumice, fly ash, slag, and/or shale. Wherepresent, the lime may be included in the cement compositions in anamount sufficient for a particular application. In some embodiments, thelime may be present in an amount in the range of from about 1% to about40% by weight of cementitious components. For example, the lime may bepresent in an amount of about 5%, about 10%, about 15%, about 20%, about25%, about 30%, or about 35%. In one embodiment, the lime may be presentin an amount in the range of from about 5% to about 20% by weight ofcementitious components. One of ordinary skill in the art, with thebenefit of this disclosure, will recognize the appropriate amount of thelime to include for a chosen application.

Embodiments of the acid-soluble cement compositions may further comprisean acid-soluble filler. The acid-soluble filler may be used, forexample, in compositions that comprise Portland cement with theacid-soluble filler providing an acid-soluble component so that thecompositions can be dissolved and removed. In an embodiment, theacid-soluble filler is present in a cement composition comprising aSorel cement. Examples of suitable acid-soluble filler include dolomite,magnesium carbonate, calcium carbonate, and zinc carbonate. Where used,the acid-soluble filler may present in the acid-soluble cementcomposition in an amount of from about 0.1% to about 300% by weight ofthe cementitious component. In an embodiment, the acid-soluble filler ispresent in an amount of from about 50% to about 400% by weight of thecementitious component. In an embodiment, the acid-soluble filler ispresent in an amount of from about 100% to about 300% by weight of thecementitious component. One of ordinary skill in the art, with thebenefit of this disclosure, will recognize the appropriate amount of theacid-soluble filler to include for a chosen application.

Embodiments of the acid-soluble cement compositions may further comprisefly ash. A variety of fly ashes may be suitable, including fly ashclassified as Class C and Class F fly ash according to AmericanPetroleum Institute, API Specification for Materials and Testing forWell Cements, API Specification 10, Fifth Ed., Jul. 1, 1990. Class C flyash comprises both silica and lime so that, when mixed with water, itshould set to form a hardened mass. Class F fly ash generally does notcontain sufficient lime, so an additional source of calcium ions isrequired for the Class F fly ash to faun a hydraulic composition. Insome embodiments, lime may be mixed with Class F fly ash in an amount inthe range of about 0.1% to about 25% by weight of the fly ash. In someinstances, the lime may be hydrated lime. Suitable examples of fly ashinclude, but are not limited to, POZMIX® A cement additive, commerciallyavailable from Halliburton Energy Services, Inc., Duncan, Okla.

Where present, the fly ash generally may be included in the acid-solublecement compositions in an amount sufficient to provide the desiredcompressive strength, density, and/or cost. In some embodiments, the flyash may be present in the cement compositions of the present inventionin an amount in the range of about 5% to about 75% by weight ofcementitious components. In some embodiments, the fly ash may be presentin an amount in the range of about 10% to about 60% by weight ofcementitious components. One of ordinary skill in the art, with thebenefit of this disclosure, will recognize the appropriate amount of thefly ash to include for a chosen application.

Embodiments of the acid-soluble cement compositions may further comprisea slag cement. In some embodiments, a slag cement that may be suitablefor use may comprise slag. Slag generally does not contain sufficientbasic material, so slag cement may further comprise a base to produce ahydraulic composition that may react with water to set to form ahardened mass. Examples of suitable sources of bases include, but arenot limited to, sodium hydroxide, sodium bicarbonate, sodium carbonate,lime, and combinations thereof.

Where present, the slag cement generally may be included in theacid-soluble cement compositions in an amount sufficient to provide thedesired compressive strength, density, and/or cost. In some embodiments,the slag cement may be present in the cement compositions of the presentinvention in an amount in the range of about 0.1% to about 99% by weightof cementitious components. In some embodiments, the slag cement may bepresent in an amount in the range of about 5% to about 75% by weight ofcementitious components. One of ordinary skill in the art, with thebenefit of this disclosure, will recognize the appropriate amount of theslag cement to include for a chosen application.

Embodiments of the acid-soluble cement compositions may further comprisemetakaolin. Generally, metakaolin is a white pozzolan that may beprepared by heating kaolin clay, for example, to temperatures in therange of about 600° C. to about 800° C. In some embodiments, themetakaolin may be present in the cement compositions of the presentinvention in an amount in the range of about 5% to about 95% by weightof cementitious components. In some embodiments, the metakaolin may bepresent in an amount in the range of about 10% to about 50% by weight ofcementitious components. One of ordinary skill in the art, with thebenefit of this disclosure, will recognize the appropriate amount of themetakaolin to include for a chosen application.

Embodiments of the acid-soluble cement compositions may further compriseshale. Among other things, shale included in the cement compositions mayreact with excess lime to foam a suitable cementing material, forexample, calcium silicate hydrate. A variety of shales may be suitable,including those comprising silicon, aluminum, calcium, and/or magnesium.An example of a suitable shale comprises vitrified shale. Suitableexamples of vitrified shale include, but are not limited to,PRESSUR-SEAL FINE LCM material and PRESSUR-SEAL COARSE LCM material,which are commercially available from TXI Energy Services, Inc.,Houston, Tex. Generally, the shale may have any particle sizedistribution as desired for a particular application. In certainembodiments, the shale may have a particle size distribution in therange of about 37 micrometers to about 4,750 micrometers.

Where present, the shale may be included in the acid-soluble cementcompositions of the present invention in an amount sufficient to providethe desired compressive strength, density, and/or cost. In someembodiments, the shale may be present in the cement compositions of thepresent invention in an amount in the range of about 5% to about 75% byweight of cementitious components. In some embodiments, the shale may bepresent in an amount in the range of about 10% to about 35% by weight ofcementitious components. One of ordinary skill in the art, with thebenefit of this disclosure, will recognize the appropriate amount of theshale to include for a chosen application.

Embodiments of the acid-soluble cement compositions may further comprisezeolite. Zeolites generally are porous alumino-silicate minerals thatmay be either a natural or synthetic material. Synthetic zeolites arebased on the same type of structural cell as natural zeolites, and maycomprise aluminosilicate hydrates. As used herein, the term “zeolite”refers to all natural and synthetic forms of zeolite. Examples ofsuitable zeolites are described in more detail in U.S. Pat. No.7,445,669. An example of a suitable source of zeolite is available fromthe C2C Zeolite Corporation of Calgary, Canada. In some embodiments, thezeolite may be present in the cement compositions of the presentinvention in an amount in the range of about 5% to about 65% by weightof cementitious components. In certain embodiments, the zeolite may bepresent in an amount in the range of about 10% to about 40% by weight ofcementitious components. One of ordinary skill in the art, with thebenefit of this disclosure, will recognize the appropriate amount of thezeolite to include for a chosen application.

Embodiments of the acid-soluble cement compositions may further comprisea set retarding additive. As used herein, the term “set retardingadditive” refers to an additive that retards the setting of theacid-soluble cement compositions of the present invention. Examples ofsuitable set retarding additives include, but are not limited to,ammonium, alkali metals, alkaline earth metals, metal salts ofsulfoalkylated lignins, organic acids (e.g., hydroxycarboxy acids),copolymers that comprise acrylic acid or maleic acid, and combinationsthereof. One example of a suitable sulfoalkylate lignin comprises asulfomethylated lignin. Suitable set retarding additives are disclosedin more detail in U.S. Pat. No. Re. 31,190, the entire disclosure ofwhich is incorporated herein by reference. Suitable set retardingadditives are commercially available from Halliburton Energy Services,Inc. under the trademarks HR® 4, HR® 5, HR® 7, HR® 12, HR®15, HR®25, HR601, SCR™ 100, and SCR™ 500 retarders. Generally, where used, the setretarding additive may be included in the cement compositions of thepresent invention in an amount sufficient to provide the desired setretardation. In some embodiments, the set retarding additive may bepresent in the cement compositions of the present invention an amount inthe range of about 0.1% to about 5% by weight of cementitiouscomponents. One of ordinary skill in the art, with the benefit of thisdisclosure, will recognize the appropriate amount of the set retardingadditive to include for a chosen application.

Optionally, other additional additives may be added to the acid-solublecement compositions of the present invention as deemed appropriate byone skilled in the art, with the benefit of this disclosure. Examples ofsuch additives include, but are not limited to, strength-retrogressionadditives, set accelerators, weighting agents, lightweight additives,gas-generating additives, mechanical property enhancing additives,lost-circulation materials, filtration-control additives, dispersants,fluid loss control additives, defoaming agents, foaming agents,oil-swellable particles, water-swellable particles, thixotropicadditives, and combinations thereof. Specific examples of these, andother, additives include crystalline silica, amorphous silica, fumedsilica, salts, fibers, hydratable clays, microspheres, rice husk ash,elastomers, elastomeric particles, resins, latex, combinations thereof,and the like. A person having ordinary skill in the art, with thebenefit of this disclosure, will readily be able to determine the typeand amount of additive useful for a particular application and desiredresult.

As will be appreciated by those of ordinary skill in the art, theacid-soluble cement compositions of the present invention may be used insubterranean operations in accordance with embodiments of the presentinvention. Without limitation, the cement composition may be used toseal off one or more subterranean zones from a well bore; to plug a voidor crack in a conduit disposed in the well bore; to plug a void or crackin a cement sheath disposed in the well bore; to plug an opening betweenthe cement sheath and the conduit; to prevent the loss of fluid from thewell bore into loss circulation zones such as a void, vug, or fracture;to form an annular plug; to isolate a gravel packed interval of the wellbore; or combinations thereof. In an embodiment, the acid-soluble cementcomposition may be used to form a selectively removable barrier (e.g., aplug, a seal, etc.) in a subterranean formation.

An example of a method of the present invention comprises placing anacid-soluble cement composition in a subterranean formation, andallowing the acid-soluble cement composition to set in the formation. Itis intended to be understood that the phrase “placing an acid-solublecement composition in the subterranean formation” encompasses placementof the cement composition in the well bore and/or placement of thecement composition in rock surrounding the well bore with the well borepenetrating the subterranean formation. The cement composition shouldform a hardened mass in the subterranean formation. The hardened masscan be left in the subterranean formation permanently or can be removed.Removal of the hardened mass may be desired so that the subterraneanformation can be utilized in subsequent hydrocarbon production inaccordance with embodiments of the present invention. In an embodiment,removal of the hardened mass includes contacting the hardened mass withan aqueous acid composition to dissolve the hardened mass. The aqueousacid composition may include, for example, from about 7.5% to about 28%hydrochloric acid by weight of the composition. In an embodiment, theaqueous acid composition includes hydrochloric acid in an amount ofabout 15% by weight.

To facilitate a better understanding of the present invention, thefollowing examples of certain aspects of some embodiments are given. Inno way should the following examples be read to limit, or define, thescope of the invention.

Example 1

A series of acid-soluble cement compositions was prepared at roomtemperature and subjected to crush strength and solubility testing. Eachof the samples contained sufficient water to provide the densityprovided in the table below and comprised various quantities of Class HPortland cement, Holcim CKD, and/or calcium carbonate, as indicated inthe table below.

Solubility Testing: For the solubility testing, each sample was pouredinto a 2-inch cube and allowed to cure in a water bath at 150° F. foreither 48 hours (Samples 1-5) or 72 hours (Samples 6-10). After curing,the sample cubes are placed in an 80° F. water bath for at least 30minutes and then weighed to determine an initial weight. Each samplecube was then submerged in 2,000 milliliters of a 15% by weighthydrochloric acid solution in a 3,000 milliliter beaker. The sample cubewas supported in the acid solution above a magnetic stir bar. Themagnetic stir bar was rotated to create a slight vortex on the surfaceof the acid solution. After 30 minutes, the sample cube was removed fromthe acid solution and weighted to determine a final weight. The acidsolubility of each composition was calculated by the following formula:

Acid Solubility=Final Weight/(Initial Weight−Final Weight)×100

Crush Strength Testing: For the crush strength testing, each sample waspoured into a 2-inch cube, allowed to cure in a water bath at 150° F.for 48 hours (Samples 1-5) or 72 hours (Samples 6-10), and then crushed.The crush strengths were determined using a Tinius Olson tester inaccordance with API Specification 10.

The results of the tests are set forth in the table below. In thefollowing table, percent by weight is based on the weight of the cementand the CKD in the samples.

TABLE 1 Crush Strength Tests: Cement, CKD, and CaCO₃ PortlandDissolution Crush Cement CKD CaCO₃ Time in Acid Strength Density (% by(% by (% by 15% HCl Solubility (psi) Sample (ppg) wt) wt) wt) (min) (%)48 Hr 72 Hr 1 15 75 25 100 30 82.72 736 — 2 15 50 50 100 30 99.01 523 —3 15 25 75 100 30 99.88 353 — 4 15 0 100 100 20 99.25 67.2 — 5 15 100 0100 30 66.46 1004 — 6 14.5 75 25 300 30 90.97 — 152 7 14.5 50 50 300 3092.61 — 108 8 14.5 25 75 300 30 93.55 — 61 9 14.5 0 100 300 30 99.38 —20 10 14.5 100 0 300 30 93.45 — 188

Example 1 thus indicates that acid-soluble cement compositionscontaining from 25% to 100% CKD by weight, from 0% to 75% Portlandcement by weight, and from 100% to 300% calcium carbonate by weight mayhave properties suitable for use in acid-soluble operations.

Example 2

An additional series of acid-soluble cement compositions was preparedand subjected to thickening time, force resistance, and rheologicaltests. Each of the samples contained sufficient water to provide thedensity provided in the table below and comprised various quantities ofClass H Portland cement, Holcim CKD, calcium carbonate, a dispersant(CFR™-3 cement friction reducer), and/or a set retarding additive, asindicated in the table below. In the following tables, percent by weightis based on the weight of the cement and the CKD in the samples.

The samples were prepared at room temperature with thickening time testsconducted at 140° F. on a portion of each composition in accordance withAPI Specification 10. The crush strength of Sample 12 was determined bypouring the sample into a 2-inch cube, allowing it to cure in a waterbath at 160° F. for 72 hours, and then crushing the cured cube. Thecrush strength was determined using a Tinius Olson tester in accordancewith API Specification 10. The results of the thickening time and forceresistance tests are provided in the table below.

TABLE 2 Thickening Time Tests: Cement, CKD, and CaCO₃ Portland CKDThickening 72-Hr Cement (% CaCO₃ Retarder Time Crush Density (% by by (%by Dispersant (% by to 70 bc Strength Sample (ppg) wt) wt) wt) (% by wt)wt) (hr:min) (psi) 11 15 50 50 100 — 0.25%  2:31 — HR ®-5 12 15 50 50100 — 0.5% 3:27 545 HR ®-5 13 16 75 25 100 0.5 0.5% 1:41 — SCR-5 ™ 14 1675 25 100 —   1% 8:42 — HR ®-5

For the rheological tests, additional portions of the acid-solublecement compositions were conditioned in an atmospheric consistometer tothe test temperature. After conditioning, the rheology of thecompositions was determined using a Fann Model 35 viscometer at thetemperature indicated in the table below using a bob and sleeve andspring #1 in accordance with the procedure set forth in APISpecification 10. The results of the rheological tests are set forth inthe table below. In the following table, percent by weight is based onthe weight of the cement and the CKD in the samples.

TABLE 3 Rheological Tests: Cement, CKD, and CaCO₃ Portland CKD Cement (%CaCO₃ Retarder Density (% by by (% by Dispersant (% by Temp. RotationsPer Minute Sample (ppg) wt) wt) wt) (% by wt) wt) (° F.) 600 300 200 10060 30 6 3 12 15 50 50 100 — 0.5% 80 76 41 30 18 14 9 6 5 HR ®-5 140 4827 21 15 12 9 8 7 13 16 75 25 100 0.5 0.5% 80 167 79 54 27 16 8 2 2SCR-5 ™ 140 52 21 12 6 4 2 1 1 14 16 75 25 100 —   1% 80 207 115 80 4733 22 12 10 HR ®-12 140 98 47 32 18 12 8 4 4

Example 2 thus indicates that acid-soluble cement compositionscontaining from 25% to 50% CKD by weight, from 50% to 75% Portlandcement by weight, and 100% calcium carbonate by weight may haveproperties suitable for use in acid-soluble operations.

Example 3

An additional acid-soluble cement composition was prepared to determineforce resistance properties of compositions comprising pumicite. Thecomposition contained sufficient water to provide the density providedin the table below and comprised Class H Portland cement, 200-meshpumicite, calcium carbonate, a set retarding additive (HR®5 retarder),and hydrated lime, as indicated in the table below. For the acidsolubility testing, the composition was poured into a 2-inch cube andcured at 180° F. for 24 hours. The acid solubility of the compositionwas then determined by submerging the cured cube in a 15% by weighthydrochloric acid solution in accordance with the procedure describedabove in Example 1. For the crush strength testing, the composition waspoured into a 2-inch cube, allowed to cure in a water bath for 24 hoursat 180° F., and then crushed. The 24-hour crush strength was determinedusing a Tinius Olson tester in accordance with API Specification 10. Theresults of the tests are set forth in the table below. In the followingtable, percent by weight is based on the weight of the cement and theCKD in the samples.

TABLE 4 Crush Strength Tests: Cement, Pumicite, and CaCO₃ PortlandDissolution 24-Hr Cement Pumicite CaCO₃ Retarder Hydrated Time in AcidCrush Density (% by (% by (% by (% by Lime (% 15% HCl SolubilityStrength Sample (ppg) wt) wt) wt) wt) by wt) (min) (%) (psi) 15 15 50 50100 0.5% 5 30 98.62 1400 HR ®-5

Example 3 thus indicates that acid-soluble cement compositionscontaining Portland cement, pumicite, and calcium carbonate may haveproperties suitable for use in acid-soluble operations.

Example 4

An additional series of acid-soluble cement compositions was prepared atroom temperature to determine force resistance properties ofcompositions comprising Sorel cement (e.g., a mixture of magnesiumchloride and magnesium oxide), CKD, and/or pumicite. Each of the samplescontained water, magnesium chloride (C-TEK), magnesium oxide (THERMATEK™LT additive), Holcim CKD, 200-mesh pumicite, and/or hydrated lime, asindicated in the table below. The crush strength of the compositions wasdetermined by pouring each composition into a 2-inch cube, allowing thecube to cure in a water bath at 140° F. for either 24 or 48 hours, andthen crushing the cured cube. The crush strengths were determined usinga Tinius Olson tester in accordance with API Specification 10. Theresults of the tests are set forth in the table below.

TABLE 5 Crush Strength Tests: Sorel Cement, CKD, and/or Pumicite CrushStrength Water MgCl2 MgO CKD Pumicite Hydrated (psi) Sample (g) (g) (g)(g) (g) Lime (g) 24 Hr 72 Hr 16 200 300 300 — — — 3460 — 17 200 300 28515 — — — 2430 18 200 300 270 30 — — — 2280 19 200 300 225 75 — — 1116 —20 200 200 225 12.5 12.5 10 — 1822 21 200 300 300 75 — — 1864 — 22 200300 285 — 15 — 3080 — 23 200 300 270 — 30 — 2790 — 24 200 300 225 — 75 —2360 — 25 200 300 225 — 75 7.5 2360 —

Example 4 thus indicates that acid-soluble cement compositionscontaining Sorel cement, cement kiln dust, and/or pumicite may haveproperties suitable for use in acid-soluble operations.

Example 5

An additional series of acid-soluble cement compositions was prepared atroom temperature to determine force resistance properties of lightweightcompositions comprising Sorel cement (e.g., a mixture of magnesiumchloride and magnesium oxide) and CKD. Each of the samples containedwater, magnesium chloride (C-TEK additive), magnesium oxide (THERMATEK™LT additive), Holcim CKD, a set retarding additive (R-TEK inhibitor),and glass bubbles (HGS 2000 glass bubbles), as indicated in the tablebelow. he crush strength of the compositions was determined by pouringeach composition into a 2-inch cube, allowing the cube to cure in awater bath at 140° F. for 24 hours, and then crushing the cured cube.The crush strengths were determined using a Tinius Olson tester inaccordance with API Specification 10. The results of the tests are setforth in the table below.

TABLE 6 Crush Strength Tests: Sorel Cement and CKD 24-Hr Glass CrushDensity Water MgCl2 MgO CKD Retarder Bubbles Strength Sample (ppg) (g)(g) (g) (g) (g) (g) (psi) 26 11.23 200 300 300 — 18 50 923 27 10.84 200300 225 75 18 50 663

Example 5 thus indicates that acid-soluble cement compositions having alightweight and containing Sorel cement and cement kiln dust may haveproperties suitable for use in acid-soluble operations.

Example 6

An additional series of acid-soluble cement compositions was prepared atroom temperature and subjected to thickening time tests at 140° F. inaccordance with API Specification 10. Each of the samples containedwater, magnesium chloride (C-TEK additive), magnesium oxide (THERMATEK™LT additive), Holcim CKD, and a retarder (R-TEK inhibitor) as indicatedin the table below. The results of the tests are set forth in the tablebelow.

TABLE 7 Thickening Time Tests: Sorel Cement and CKD Thickening TimeWater MgCl2 MgO CKD Retarder to 70 bc Sample (g) (g) (g) (g) (g)(hr:min) 28 200 300 225 75 5 00:36  29 200 300 225 75 9 1:13 30 200 300225 75 18 1:11

Example 6 thus indicates that acid-soluble cement compositionscontaining Sorel cement and cement kiln dust may have propertiessuitable for use in acid-soluble operations.

Therefore, the present invention is well adapted to attain the ends andadvantages mentioned as well as those that are inherent therein. Theparticular embodiments disclosed above are illustrative only, as thepresent invention may be modified and practiced in different butequivalent manners apparent to those skilled in the art having thebenefit of the teachings herein. Although individual embodiments arediscussed, the invention covers all combinations of all thoseembodiments. Furthermore, no limitations are intended to the details ofconstruction or design herein shown, other than as described in theclaims below. It is therefore evident that the particular illustrativeembodiments disclosed above may be altered or modified and all suchvariations are considered within the scope and spirit of the presentinvention. While compositions and methods are described in terms of“comprising,” “containing,” or “including” various components or steps,the compositions and methods can also “consist essentially of” or“consist of” the various components and steps. Whenever a numericalrange with a lower limit and an upper limit is disclosed, any number andany included range falling within the range is specifically disclosed.In particular, every range of values (of the form, “from about a toabout b,” or, equivalently, “from approximately a to b,” or,equivalently, “from approximately a-b”) disclosed herein is to beunderstood to set forth every number and range encompassed within thebroader range of values. Also, the terms in the claims have their plain,ordinary meaning unless otherwise explicitly and clearly defined by thepatentee.

What is claimed is:
 1. An acid-soluble cement composition comprising:hydraulic cement; a component selected from the group consisting ofcement kiln dust, pumicite, and a combination thereof; and water,wherein the acid-soluble cement composition has a solubility of at leastabout 83% when contacted for 30 minutes by an aqueous acid compositioncomprising 15% hydrochloric acid by weight of the acid-soluble cementcomposition.
 2. The composition of claim 1 wherein the acid-solublecement composition has a density of about 8 pounds per gallon to about16 pounds per gallon, and wherein the water is present in an amount ofabout 40% to about 200% by weight of cementitious components in theacid-soluble cement composition.
 3. The composition of claim 1 whereinthe hydraulic cement comprises a hydraulic cement selected from thegroup consisting of a Portland cement, a pozzolana cement, a gypsumcement, a high alumina content cement, a slag cement, a silica cement,and any combination thereof.
 4. The composition of claim 1 wherein thehydraulic cement comprises a Sorel cement.
 5. The composition of claim 1wherein the hydraulic cement comprises a magnesium oxide and a magnesiumchloride.
 6. The composition of claim 1 wherein the hydraulic cement ispresent in an amount of about 0% to about 20% by weight of cementitiouscomponents in the acid-soluble cement composition.
 7. The composition ofclaim 1 wherein the component comprises the cement kiln dust in anamount of about 20% to about 100% by weight of cementitious componentsin the acid-soluble cement composition.
 8. The composition of claim 1wherein the component comprises the pumicite in an amount of about 20%to about 100% by weight of cementitious components in the acid-solublecement composition.
 9. The composition of claim 8 wherein theacid-soluble cement composition further comprises a source of calciumions.
 10. The composition of claim 1 wherein the acid-soluble cementcomposition further comprises hydrated lime in an amount of about 1% toabout 40% by weight of cementitious components in the acid-solublecement composition.
 11. The composition of claim 1 wherein theacid-soluble cement composition further comprises an acid-solublefiller.
 12. The composition of claim 12 wherein the acid-soluble fillercomprises a material selected from the group consisting of dolomite,magnesium carbonate, calcium carbonate, zinc carbonate, and anycombination thereof.
 13. The composition of claim 1 wherein theacid-soluble cement composition further comprises an additive selectedfrom the group consisting of fly ash, slag cement, metakaolin, shale,zeolite, crystalline silica, amorphous silica, fumed silica, salt,fiber, hydratable clay, microsphere, rice husk ash, elastomer,elastomeric particle, resin, latex, and any combination thereof.
 14. Thecomposition of claim 1 wherein the acid-soluble cement compositionfurther comprises an additive selected from the group consisting of aset retarding additive, a strength-retrogression additive, a setaccelerator, a weighting agent, a lightweight additive, a gas-generatingadditive, a mechanical property enhancing additive, a lost-circulationmaterial, a filtration-control additive, a dispersant, a fluid losscontrol additive, a defoaming agent, a foaming agent, an oil-swellableparticle, a water-swellable particle, a thixotropic additive, and anycombination thereof.
 15. The composition of claim 1 wherein thesolubility of the acid-soluble cement composition is at least about 90%when contacted for 30 minutes by the aqueous acid composition comprising15% hydrochloric acid by weight of the acid-soluble cement composition.16. A acid-soluble cement composition comprising: 0% to about 20%Portland cement by weight of cementitious components present in theacid-soluble cement composition; cement kiln dust; an acid-solublefiller; and water, wherein the acid-soluble cement composition has asolubility of at least about 83% when contacted for 30 minutes by anaqueous acid composition comprising 15% hydrochloric acid by weight ofthe acid-soluble cement composition.
 17. The composition of claim 16wherein the cement kiln dust is present in an amount of about 70% toabout 100% by weight of the cementitious components in the acid-solublecement composition.
 18. The composition of claim 16 wherein the cementkiln dust is present in an amount of about 90% to about 100% by weightof the cementitious components in the acid-soluble cement composition.19. The composition of claim 16 wherein the acid-soluble fillercomprises a material selected from the group consisting of dolomite,magnesium carbonate, calcium carbonate, zinc carbonate, and anycombination thereof.
 20. The composition of claim 16 wherein theacid-soluble filler is present in an amount of about 50% to about 400%by weight of the cementitious components in the acid-soluble cementcomposition.
 21. The composition of claim 16 wherein the acid-solublefiller comprises the calcium carbonate and is present in an amount ofabout 10% to about 300% by weight of the cementitious components in theacid-soluble cement composition.
 22. The composition of claim 16 whereinthe solubility of the acid-soluble cement composition is at least about90% when contacted for 30 minutes by the aqueous acid compositioncomprising 15% hydrochloric acid by weight of the acid-soluble cementcomposition.
 23. An acid-soluble cement composition comprising:hydraulic cement; pumicite in an amount of about 20% to about 100% byweight of cementitious components present in the acid-soluble cementcomposition; and water, wherein the acid-soluble cement composition hasa solubility of at least about 83% when contacted for 30 minutes by anaqueous acid composition comprising 15% hydrochloric acid by weight ofthe acid-soluble cement composition.
 24. The composition of claim 23wherein the acid-soluble cement composition further comprises anacid-soluble filler selected from the group consisting of dolomite,magnesium carbonate, calcium carbonate, zinc carbonate, and anycombination thereof.
 25. The composition of claim 23 wherein theacid-soluble cement composition further comprises an acid-soluble fillerpresent in an amount of about 50% to about 400% by weight of thecementitious components in the acid-soluble cement composition.
 26. Thecomposition of claim 23 wherein the acid-soluble cement compositionfurther comprises calcium carbonate in an amount of about 10% to about300% by weight of the cementitious components in the acid-soluble cementcomposition.
 27. The composition of claim 23 wherein the solubility ofthe acid-soluble cement composition is at least about 90% when contactedfor 30 minutes by the aqueous acid composition comprising 15%hydrochloric acid by weight of the acid-soluble cement composition.